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Bespoke 800A Main LV Switchgear Upgrade for the MOD

Posted: 26 February 2026

Project details

Last year we completed a critical power infrastructure upgrade at a Ministry of Defence site, centred around the design, manufacture, and installation of a bespoke 800A Main LV Switchgear panel. The site’s existing electrical system, originally installed in the 1980s, required full modernisation to support a newly specified AS400 400kVA diesel generator and to meet current operational resilience standards. CPS was appointed directly as both the generator and LV switch panel supplier and installer, following previous successful projects delivered for the MOD.

From initial site survey through to commissioning and handover, the project was delivered within a three-month programme.

Project overview

The introduction of the new generator required a completely re-engineered switchgear solution capable of managing changeover, distribution, and load testing safely and efficiently within a high-security defence environment.

CPS designed and manufactured a bespoke 800A Main LV Switchgear panel tailored specifically to integrate with the upgraded generator system and the site’s existing infrastructure. The panel was engineered in a wall or floor-standing configuration to suit the plant room layout, with top-mounted cable entry points on both the left and right-hand sides to allow flexible routing and future expansion.

Project scope

The switchgear was built to accommodate robust internal segregation, integrated control components, and future service access. An ABB 800A automatic changeover system was incorporated to ensure reliable and secure transfer between the mains supply and the new standby generator. Within a Ministry of Defence setting, uninterrupted transfer and dependable operation are critical to maintaining essential services, making this a core feature of the upgrade.

To ensure the newly installed generator system can be regularly tested and validated, the switchgear was designed with integrated load bank controls and a dedicated breaker to support a 500kW resistive load bank.

By embedding load bank functionality directly into the LV panel, CPS provided the site with a safe and controlled method of carrying out performance testing without temporary modifications or external cabling. This improves operational safety, simplifies maintenance procedures, and ensures the standby power system can be validated in line with defence site requirements.

The inclusion of a mimic control panel with LCD display further enhances usability, providing real-time monitoring of voltage levels, fuel status, and overall system performance. This level of visibility supports efficient fault diagnosis and ongoing system management.

Installation & Project Delivery

The project began with a detailed site survey and full design works to ensure seamless integration between the new generator and the upgraded switchgear. Given the remote location and challenging weather conditions, logistics were carefully planned with specialist HIAB and crane support to guarantee safe delivery and precise positioning.

Despite environmental challenges, installation, commissioning, and testing were completed efficiently, followed by full training and handover documentation including O&M manuals and QHSE records.

By upgrading the Main LV Switchgear in conjunction with the new AS400 generator installation, the MOD site now benefits from improved resilience, controlled load testing capability, and modernised system monitoring.

This project demonstrates CPS’s expertise in delivering bespoke, UK-manufactured LV switchgear solutions engineered specifically to support standby generator systems within high-security and mission-critical environments.

To learn more about the wider generator installation that formed part of this project, you can read the full generator case study here.

If you are planning an electrical infrastructure upgrade or require bespoke LV switchgear designed around your generator and operational requirements, contact our team to discuss your project.